System and process for production of magnesium metal and magnesium hydride from magnesium-containing salts and brines

ABSTRACT

A system and process are disclosed for production of consolidated magnesium metal products and alloys with selected densities from magnesium-containing salts and feedstocks. The system and process employ a dialkyl magnesium compound that decomposes to produce the Mg metal product. Energy requirements and production costs are lower than for conventional processing.

STATEMENT REGARDING RIGHTS TO INVENTION MADE UNDER FEDERALLY-SPONSORED RESEARCH AND DEVELOPMENT

This invention was made with Government support under Contract DE-ACO5-76RLO1830 awarded by the U.S. Department of Energy. The Government has certain rights in the invention.

FIELD OF THE INVENTION

The present invention relates to a system and process for production of magnesium metal or magnesium hydride from magnesium-containing salts recovered from seawater, mining, or other process waste streams.

BACKGROUND OF THE INVENTION

Demand for magnesium (Mg) metal is increasing rapidly due to uses in lightweight high strength alloys for automobiles, aerospace, and building construction. However, worldwide supply is flat or declining. Seawater represents a virtually unlimited source of Mg that could supply worldwide demand if an economically and environmentally sound method were available for its extraction. Mg is commonly obtained from the high temperature Pidgeon process in which a Mg-bearing mineral such as dolomite is reacted with FeSi. Mg is also obtained by electrolysis of MgCl₂ salts recovered from seawater or other brine sources such as the Great Salt Lake (UT, USA). However, conventional electrolysis of molten salts requires high purity (94% or better) MgCl₂ salts. High-purity MgCl₂ salts are presently obtained through a complex series of steps including precipitation, solvent extraction, water evaporation, dehydration of MgCl₂.nH₂O salts, and high-temperature carbothermic reduction of impure salts recovered as evaporates from spray-dried brines. However, water evaporation from MgCl₂ brines and dehydration of MgCl₂.nH₂O salts prior to MgCl₂ electrolysis are energy intensive steps. The only remaining commercial operation in the U.S. for production of Mg metal (U.S. Magnesium, LLC, Salt Lake City, Utah, USA) produces Mg from water taken from the Great Salt Lake (Utah, USA). This high-temperature plant requires 44 kWh/kg of energy at a production cost of $3.31/kg. However, in its Modern Electro/Thermochemical Advances In Light Metal Systems (METALS) program, the Advanced Research Projects Agency-Energy (ABPA-E) set ambitious target goals for both energy (27 kWh/kg) and cost of production ($2/kg). Accordingly, new processes are needed that produce Mg at these much lower energy and production costs in addition to dramatically lowering peak process temperatures (<350° C.). The present invention addresses these needs.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an exemplary system of the present invention for production of magnesium metal from magnesium-containing salts and brines.

FIG. 2 shows a process for generating hydrometallation catalysts used in a hydrometallation reaction in concert with the present invention.

FIG. 3 shows an exemplary configuration for performing catalyzed organo-metathetical (COMET) production of magnesium metal in concert with the present invention.

SUMMARY OF THE PRESENT INVENTION

The present invention includes a system for production of magnesium metal or magnesium hydride from magnesium-containing salts and brines. Magnesium-containing salts and brines may be obtained from various sources including, but not limited to, e.g., seawater, mineral tailings and effluents, salt brines, and combinations of these various sources. The system may include a metallation stage configured to carry out a reaction between anhydrous magnesium-containing salt with an alkyl-lithium (RLi) compound at a selected temperature and pressure to form a dialkyl magnesium (MgR₂) compound. A decomposition stage or reactor may be configured to decompose the dialkyl magnesium compound received from the metallation stage at a selected temperature which produces magnesium metal or magnesium hydride with a selected density at a selected yield.

The system may further include a hydrometallation stage that reacts lithium (Li) metal and an olefin over a selected catalyst to form the alkyl lithium compound supplied to the metallation stage.

The decomposition reactor may decompose the dialkyl magnesium (MgR₂) compound in an inert atmosphere or under vacuum at a temperature above 150° C. that forms either magnesium hydride or Mg metal product at a yield greater than or equal to about 90%. Time, temperature, and gas composition maintained in the decomposition reactor control production yield of the desired end product.

The present invention also includes a process for catalyzed organo-metathetical (COMET) production of magnesium metal (Mg) from magnesium-containing salts and brines. The COMET process of the present invention is a low-energy process that produces Mg metal from organomagnesium salts and other magnesium-containing compounds over selected catalysts at low-temperatures. The process may include forming a dialkyl magnesium (MgR₂) compound by reaction of an anhydrous magnesium-containing salt with an alkyl-lithium (RLi) compound at a selected temperature. Decomposition of the dialkyl magnesium compound at a selected temperature may form a magnesium metal or a magnesium hydride product at a selected yield and a selected density.

Forming the alkyl-lithium compound may include reacting a phenylbutylthioether immobilized on a solid support with lithium metal and recovering the alkyl-lithium compound as an unattached moiety.

Decomposition of the dialkyl magnesium compound may be performed at a temperature greater than or equal to about 150° C.

The Mg metal product may be a fully consolidated (dense) metal product. Or, the Mg metal product may be a partially consolidated metal product with selected densities.

Decomposition of the dialkyl magnesium compound may include formation of MgH₂ that assists consolidation of the Mg metal.

Decomposition of the dialkyl magnesium compound may also form alkenes as a by-product with a carbon number between about C₂ to about C₈.

The anhydrous magnesium-containing salt may include anhydrous MgCl₂.

In some embodiments, the alkyl-lithium compound and the dialkyl magnesium compound may include an alkyl group with a carbon number between about C₂ to about C₈. In some embodiments, the alkyl group may be a butyl group.

The purpose of the foregoing abstract is to enable the United States Patent and Trademark Office and the public generally, especially the scientists, engineers, and practitioners in the art who are not familiar with patent or legal terms or phraseology, to determine quickly from a cursory inspection the nature and essence of the technical disclosure of the application. The abstract is neither intended to define the invention of the application, which is measured by the claims, nor is it intended to be limiting as to the scope of the invention in any way.

DETAILED DESCRIPTION

The present invention includes a system and process for production of Mg metal or Mg hydride (MgH₂) from Mg-containing salts obtained from such sources as seawater, salt brines, mining byproducts, or other process streams. In the following description, embodiments of the present invention are shown and described by way of illustration of the best mode contemplated for carrying out the invention. It will be apparent that the invention is susceptible of various modifications and alternative constructions. The present invention covers all modifications, alternative constructions, and equivalents falling within the spirit and scope of the invention as defined in the claims. Therefore the description should be seen as illustrative and not limiting.

FIG. 1 is a schematic showing an exemplary system 100 of the present invention that provides catalyzed organo-metathetical (COMET) production of MgH₂ or Mg metal 2. The term “metathetical” used herein refers to the chemical transfer of alkyl groups 4 from an alkyl lithium compound 6 to anhydrous MgCl₂ 8 that yields a dialkylmagnesium (MgR₂) compound 10 that may be subsequently reduced to form MgH₂ or to form Mg metal 2. System 100 may include a metallation reactor 12 that forms the dialkylmagnesium (MgR₂) compound 10. System 100 may also include a decomposition stage or reactor 14 that decomposes the dialkyl-magnesium (MgR₂) compound 10 to form MgH₂ or Mg metal.

The process is flexible and yields Mg metal products and MgH₂ products having selected forms. For example, the Mg metal product may be a fully consolidated (fully dense) Mg metal product or a partially consolidated Mg metal product. Fully consolidated forms of the Mg metal product may include, but are not limited to, e.g., ingots and other monolithic forms with no internal voids or air pockets. Partially consolidated forms of the Mg metal product may include, but are not limited to, e.g., powders, particles, granules, nuggets, flakes, and other like forms. Decomposition of the present invention yields the selected metal product in the selected form without the need for energy-intensive high-temperature melting employed conventionally.

System 100 may also include a hydrometallation (catalyst) reactor 16 described further herein that forms or regenerates the alkyl-lithium compound 6 deployed in metallation reactor 12. Lithium metal (Li) 18 deployed in hydrometallation reactor 16 may be obtained in an electrolysis stage 20 from electrolytic reduction of lithium-containing salts including, e.g., LiCl 22 released from metallation reactor 12.

An azeotropic dehydrator stage 24 may be coupled to provide anhydrous MgCl₂ salt 8 as a feedstock to metallation reactor 12. Azeotropic salt mixtures delivered to azeotropic dehydrator 24 may be provided from a crystallization stage 26. A water separation stage 28 may be coupled to remove excess free water from seawater or salt brine feedstocks containing magnesium-containing salts introduced to crystallization stage 26. Each of these reactors and stages will be described in further detail below.

Metallation Reactor and Process for Production of MgR₂

System 100 may include a metallation reactor 12 configured to form or regenerate a dialkylmagnesium (MgR₂) compound 10 (e.g., dibutylmagnesium) from a reaction between anhydrous MgCl₂ 8 and an alkyl-lithium (RLi) compound 6 in a transmetallation reaction shown in [1]: MgCl₂+2RLi→MgR₂+2LiCl  [1]

Transmetallation reaction [1] is stoichiometric. Transmetallation can proceed spontaneously at temperatures at or below about 80° C. Temperatures may be selected to prevent decomposition of RLi 6.

In some embodiments, temperatures for transmetallation may be selected at or below about 60° C. In some embodiments, transmetallation may be selected at temperatures as low as, e.g., 50° C. In some embodiments, temperatures for transmetallation may be selected between about 25° C. to about 40° C. In various embodiments, reaction times may be selected up to about 24 hours. However, reaction times are not intended to be limited.

Anhydrous MgCl₂ 8 may be received from dehydration stage 24. The alkyl-lithium (RLi) compound 6 is received from a hydrometallation reactor 16 described further herein. The reaction includes a metathetical exchange of Li with Mg. Dialkyl magnesium (MgR₂) 10 is an intermediate compound used to produce MgH₂ or Mg metal 2 in a decomposition reactor 14 described further herein.

In some embodiments, yield of the dialkyl magnesium (MgR₂) compound (e.g., MgBu₂) 10 is greater than about 90%. In some embodiments, yield of the dialkyl magnesium (MgR₂) compound is greater than about 95%.

In various embodiments, the alkyl group (R) in the alkyl-lithium compound 6 and the dialkyl magnesium compound 10 may include a carbon number from about C₂ to about C₈. In the exemplary embodiment, the alkyl group may be a butyl group. The alkyl group may be in the n-alkyl form and/or the 2-alkyl form. In some embodiments, the MgR₂ intermediate 10 may be dibutyl magnesium (MgBu₂).

Transmetallation reaction [1] may be performed in selected solvents. Solvents suitable for use include, but are not limited to, e.g., ethers, hexanes, cycloalkanes including, e.g., cyclohexanes, heptanes and like solvents that maximize yield and minimize unwanted reaction products.

Transmetallation reaction [1] in metallation reactor 12 also forms LiCl 22 as a reaction by-product. LiCl 22 may be electrolyzed, e.g., in an electrolysis stage 20 described further herein to provide (Li) metal 26 and chlorine gas (Cl₂) 32. Li metal 26 may be recycled to a hydrometallation (catalyst) reactor 16 for regeneration of alkyl lithium (RLi) 6 described further herein.

Use of anhydrous MgCl₂ 8 in the metallation reactor 12 minimizes formation of undesired reaction products such as MgO and Mg(OH)Cl that can result from the reaction of MgBu₂ with water. Formation of reaction products other than MgR₂ 10 in metallation reactor 12 can lead to lower yields of Mg metal 2 during decomposition of MgBu₂ 10 or require additional processing. For example, side reaction products containing magnesium such as MgO and Mg(OH)Cl if produced can be recovered and converted back to the anhydrous MgCl₂ salt form, e.g., by exposing them to anhydrous HCl at temperatures greater than or equal to about 120° C. Recovered MgCl₂ 10 can then be fed back into metallation reactor 12 in the anhydrous MgCl₂ 8 feedstock.

Formation of reactive compounds such as trialkyl-magnesiates (Bu₃MgLi) in metallation reactor 12 can also interfere with formation of MgBu₂ 10. Trialkyl-magnesiates can form as 1:1 adducts between BuLi 6 and dibutyl magnesium (MgBu₂) 10 in metallation reactor 12 that reduces the subsequent yield of pure magnesium 2 in decomposition reactor 14. Formation of reactive trialkyl-magnesiates can be reduced or minimized by addition of bicyclic diamine donors in the solvent.

The dialkyl magnesium compound (e.g., MgBu₂) 10 released from metallation reactor 12 may be delivered to a decomposition reactor 14 to obtain Mg hydride or Mg metal product 2, as detailed hereafter.

MgBu₂ Decomposition Reactor

System 100 may also include a decomposition reactor (stage) 14 that decomposes the dialkyl magnesium (MgR₂) compound 10 received as an input from metallation reactor 12 and forms either MgH₂, or a Mg metal product 2. The term “decomposition” refers to the release of respective chemical constituents from the disassociation of the MgR₂ compound for further processing.

Process I

In some embodiments, the MgR₂ compound 10 may decompose directly to Mg metal 2, as shown for a representative di-butyl-magnesium (e.g., MgBu₂) compound 10 in [2]: MgBu₂→Mg°+2C₄H₈(g)+H₂(g)  [2]

Complete decomposition of MgBu₂ 10 in an inert atmosphere or under vacuum yields Mg metal 2 and decomposition products including alkenes 28 such as butene and hydrogen gas 30 that may be recovered. Alkene hydrocarbons may include a carbon number preferably between about C₂ to about C₄. But carbon number is not intended to be limited.

Decomposition of the MgR₂ compound 10 (e.g., MgBu₂) may be performed at conditions selected to control the structure (e.g., microstructure) and morphology of the Mg metal product 2. Conditions may include, but are not limited to, e.g., selected hydrogen pressures, selected temperatures, and selected reaction or processing times.

In some embodiments, decomposition temperature may be about 400° C. at atmospheric pressure (i.e., not in vacuum).

In some embodiments, the Mg metal product 2 may be hot pressed to form a fully consolidated (dense) metal product.

In some embodiments, the Mg metal product 2 may be a partially consolidated metal product with a selected density.

Process II

In some embodiments, decomposition of the MgR₂ compound 10 may include formation of MgH₂ and release of unsaturated hydrocarbons (e.g., alkenes) from the decomposition reaction, which may be collected as end products. For example, in some embodiments, decomposition temperature may be selected to be less than about 300° C. to form MgH₂ in vacuum (e.g., 10⁻² Torr).

In some embodiments, decomposition of the MgR₂ compound 10 may include formation of Mg metal and release of both unsaturated hydrocarbons (e.g., alkenes) and H₂ from the decomposition reaction, both of which may be collected as end products.

Process III

In some embodiments, decomposition of the MgR₂ compound 10 may first form MgH₂ as an intermediate product, as shown in [3]: MgBu₂→MgH₂+2C₄H₈(g)  [3]

In this reaction, MgBu₂ 10 (a representative MgR₂ compound) may decompose in the decomposition reactor 14 in an inert atmosphere at a temperature of about 250° C. Decomposition of the MgBu₂ releases hydrocarbons in the form of alkenes such as butene while Mg extracts hydrogen from the alkyl groups forming MgH₂. The MgH₂ product may be obtained in the form of powders, granules, and particles. Particle size may be selected by controlling reactor conditions such as, e.g., temperature ramp rate and material agitation. Hydrocarbons released in decomposition reactor 14 may be collected and provided to hydrometallation reactor 16 for catalytic regeneration of RLi 6 (e.g., n-BuLi). The MgH₂ product may also be collected as a separate end product, or may be processed further as described hereafter.

The MgH₂ intermediate may be sintered to form the Mg metal product 2, as shown in [4]: MgH₂→Mg°+H₂(g)  [4]

The term “sintering” refers to a consolidation process in which small particles or pellets of the MgR₂ compound 10 or the MgH₂ compound may be compressed and/or heated to form a dense or semi-dense Mg metal product 2. The Mg product may be in the form of ingots or other transportable forms. Hydrogen present in the MgH₂ compound may assist the consolidation and formation of the Mg metal under pressure. Hydrogen gas released from MgH₂ upon Mg metal formation may be collected and/or recycled. Density of the Mg metal product may be controlled by selection and control of process conditions in the decomposition reactor. For example, the high density of crystal lattice defects in the metal accelerates sintering of the metal as the hydride decomposes, which can facilitate diffusion of any alloying elements, can reduce formation of oxides, and can lower activation energy for decomposition of the hydride which contributes to a fine-grained microstructure and a consolidated (i.e., fully dense) Mg metal product.

In some embodiments, the MgH₂ intermediate may be sintered to produce a fully consolidated (dense) Mg metal product.

In some embodiments, MgH₂ may be sintered at a temperature less than or equal to about 450° C., which releases hydrogen from the MgH₂ intermediate compound that aides formation of a consolidated (dense) Mg metal product. In some embodiments, MgH₂ may be simultaneously sintered to release hydrogen that aids consolidation, and compressed under selected compression loads to form the consolidated Mg metal product 2. In some embodiments, consolidation may include compressing the Mg metal product under a compression load of, e.g., 1000 atm at room temperature.

In some embodiments, MgH₂ may be sintered at temperatures greater than or equal to about 350° C. to release hydrogen gas that aides consolidation of the Mg metal product 2.

In some embodiments, MgH₂ may be simultaneously sintered at a temperature of about 300° C. to release hydrogen and compressed under selected compression loads to aid consolidation of the Mg metal product 2.

In some embodiments, sintering of the MgH₂ may include extruding the MgH₂ under selected compression loads to compress the metal hydride that yield a fully consolidated or dense Mg metal product 2.

Yields of Mg metal (calculated on a MgH₂ basis) may be over 99%.

In some embodiments, sintering of the MgH₂ may produce a partially consolidated Mg metal product with selected densities. A partially consolidated Mg product may be produced by incompletely sintering MgH₂ powders such that the product includes selected gaseous voids and thus lower densities.

In some embodiments, the process may include mixing and sintering powders of MgR₂, MgH₂, Mg metal, and/or other metals and elements together to produce various Mg-containing alloys.

Materials consolidated in concert with the present invention including, e.g., MgR₂, MgH₂, Mg metal, and/or other metals and elements may include particles with sizes between about 5 nanometers (nm) to about 5 millimeters (mm).

In some embodiments, the consolidated Mg metal may be in the form of dense ingots (e.g., “pigs”). Ingots may be produced directly during sintering of MgH₂ without melting or without casting the Mg metal at conventional consolidation temperatures exceeding 700° C. For example, in some embodiments, Mg ingots may be formed by hot pressing MgH₂ formed in the decomposition reactor. Ingots may have a size and weight selected for transport or shipment in large or small quantities. In ingot form, bulk Mg metal is chemically stable and does not readily react with O₂ or H₂O in the air making the metal suitable for transport or shipment. In some embodiments, ingots may be of a size greater than about 1 lb (2.2 kg). Hot pressing may also be used to produce other magnesium-containing metal alloys.

Hydrometallation Stage

System 100 may also include a hydrometallation stage 16 configured to form or regenerate alkyl lithium compounds 6 deployed in the metallation reactor 12 (FIG. 1). Alkyl lithium (RLi) compounds 6 may be synthesized or regenerated by reacting lithium metal 26 with an olefin (alkene) 28 such as butene 28 and hydrogen. Oxidation of Li metal 26 in the presence of H₂ yields lithium hydride, as shown in [5]: Li(s)+½H₂(g)→LiH(s)  [5]

Reaction [5] proceeds spontaneously at temperatures less than about 150° C. at a high yield greater than about 90%. Reaction [5] may also be performed at a low temperature below 30° C. with a yield of LiH of about 60%. Li metal used in reaction [5] may be obtained from electrolysis of lithium-containing salts such as LiCl 22 in an electrolysis stage 20 described further herein.

LiH obtained from reaction [5] may react in a hydrometallation reaction with an alkene 28 (e.g., butene) over a selected catalyst to form an alkyl lithium compound (RLi) 6 used in metallation reactor 12, as shown in [6]: LiH(s)+C₄H₈(g)→BuLi  [6]

Hydrometallation is a thermodynamically favorable reaction. In the exemplary embodiment, LiH may react with butene to form 2-butyl-lithium and/or n-butyl-lithium. The alkene (e.g., butene) used in the hydrometallation reaction [6] may be obtained from decomposition reactor 14 described previously herein.

Resulting alkyl lithium compounds may be used in the metallation reactor 12 to form the dialkyl magnesium intermediate 10. Reaction conditions for synthesis and regeneration of the RLi compound 6 in hydrometallation stage 16 may include selected temperatures, pressures, and operation times. Process temperatures depend in part on solvents selected for operation. In some embodiments, temperatures may be selected from about −78° C. to about 100° C. In some embodiments, temperatures may be selected from about 200° C. to about 300° C.

Reaction pressures and hydrogen partial pressures may be selected from about 1 atm (9.65×10¹ kPa) to about 100 atm (9.65×10³ kPa).

Times for operation may be selected from about 15 minutes to about 24 hours.

Solvents suitable for use in hydrometallation stage 16 that promote stabilization of the alkyl lithium product 6 (e.g., BuLi) may include, but are not limited to, e.g., ethers, THF, Et₂O, DME, inert non-polar solvents including, e.g., hexanes, pentanes, toluenes, and benzenes. In the exemplary embodiment, BuLi is unstable in some solvents like THF at temperatures above 0° C. However, process temperatures may be selected below 0° C. from about −35° C. to about −78° C. to allow processing. And, while BuLi is stable in non-polar solvents including, e.g., hexane and benzene at temperatures up to 60° C., desired reactions may be slower in these solvents. Thus, higher temperatures may be used. All temperatures as will be selected by those of ordinary skill in the art in view of the disclosure are within the scope of the present invention. No limitations are intended.

Yield of Alkyl Lithium

Yields of the alkyl-lithium compound obtained from the hydrometallation reaction [6] are not intended to be limited. In some embodiments, yield of the alkyl-lithium product is greater than or equal to about 25%. In some embodiments, yield is greater than or equal to about 50%. In some embodiments, yield is greater than or equal to about 75%. In some embodiments, yield is between about 25% to about 50%. In some embodiments, yield is between about 50% to about 75%. In some embodiments, yield is between about 75% to about 90%. In some embodiments, yield is greater than or equal to about 90%.

Hydrometallation Catalysts

In some embodiments, catalysts for the hydrometallation reaction [6] that forms or regenerates RLi 6 in hydrometallation reactor 16 (FIG. 1) may be selected from Group-IIIB through Group-IVB salts that favor formation of the alkyl lithium compound (e.g., BuLi) 6 over butene, 1-butene, or LiH.

In some embodiments, catalysts may be unsubstituted catalysts such as, e.g., TiCl₄ and/or ZrCl₄ that also promote hydrometallation and form metal alkyls, which in turn can undergo transmetallation with Li metal to form the desired alkyl Li compound 6.

In some embodiments, catalysts for the hydrometallation reaction [6] may be mono-substituted catalysts of the form RTiCl₃. R-groups may include substituted or unsubstituted cyclopentadienyl (Cp) ligands, substituted or unsubstituted pyrroles, and/or tri-alkyl or tri-aryl phosphinimines.

In other embodiments, catalysts for the hydrometallation reaction [6] may be di-substituted catalysts of the form R₂TiCl₂, where (R) is a substituted or unsubstituted cyclopentadiene (Cp) ligand, a tri-alkyl, or a tri-aryl phosphinimine.

In yet other embodiments, catalysts for the hydrometallation reaction may be di-substituted catalysts of the form R₂M(X)₂ or R₂M(X)(L), where (R) is a substituted or unsubstituted cyclopentadiene ligand (Cp); (M) is a transition metal such as Ti or Zr; (X) is Cl, Br, and/or I; and the ligand (L) is a substituted or unsubstituted pyrrole, amine, or phosphinimine.

In some embodiments, catalysts may include activators such as, e.g., functionalized amines that promote formation of RLi. Functionalized amines may include triethylamine, N,N,N′,N′-tetramethylethylenediamine, and 4-methylmorpholine that may further include tertiary amine groups and/or alkyl ethers (OR).

FIG. 2 shows a process 200 for generating selected titanium-based catalysts for the hydrometallation reaction [6]. In the figure, e.g., a TiCl₄ catalyst may be modified by reaction with, e.g., a sodium cyclopentadiene (Cp) salt (e.g., a first equivalent) in a selected solvent (e.g., THF) to form a mono-substituted CpTiCl₃ catalyst. The mono-substituted CpTiCl₃ catalyst may then be reacted with a lithium salt such as, e.g., LiNR to form a di-substituted CpTiNRCl₂ catalyst. The LiNR compound may include R-groups that include alkyl groups with a carbon number between C₁ and C₁₀ including, e.g., methyl, ethyl, propyl, butyl, pentyl, and like isomers, and nitrogen-containing ligands (NR) including, e.g., methyl amine, ethyl amine, propyl amine, iso-propyl amine, and like ligands. The CpTiNRCl₂ catalyst may be further reacted with another equivalent of a sodium cyclopentadiene (Cp) to form a tri-substituted Cp₂TiNRCl catalyst.

In some embodiments, catalysts for the hydrometallation reaction [6] may be di-substituted catalysts of the general form shown in [7]:

In some embodiments, catalysts for the hydrometallation reaction [6] may be tri-substituted catalysts. Here, (M) may be a transition metal such as Ti or Zr. The catalyst may be further modified with selected ligands (L) that replace a (Cl) of the coordinated metal (M) as shown in [8]:

Ligands may be selected that favor formation of the alkyl lithium (RLi) compound in the hydrometallation reaction [6] described previously herein. Ligands (L) may include, but are not limited to, e.g., pyrroles, substituted pyrroles, phosphinimines, and ligands having the general form in [9]: —N═PAr₃  [9]

Here, (Ar) may be any aryl group including, but not limited to, e.g., anisol, anisol derivatives [e.g., H₃COPh—]; aniline, aniline derivatives including, e.g., alkyl anilines, and dialkyl anilines [e.g., (H₃C)₂NPh]; toluene, toluene derivatives including, alkyl toluenes [e.g., H₃CPh]; and like ligands.

In other embodiments, ligands (L) may include substituted and unsubstituted cyclopentadiene (Cp) groups. Substituted (Cp) ligands may include selected functional (R) groups and chemical moieties including, e.g., alkoxides (RO) including, e.g., alcohols, ethers; pendant (attached) alkyl groups (e.g., methyl (Me); alkyl amines (e.g., dimethyl amines [Me₂N], diethyl amines [Et₂N], dipropyl amines [Pr₂N], dibutyl amines [Bu₂N], and like amines; and alkyl silanes [RSi] and like groups.

In other embodiments, ligands may be modified with electron-donating groups. Groups that introduce steric bulk can also be employed to weaken carbon (C) metal (M) bonds that facilitate hydrometallation. Catalyst ligands may also be selected that stabilize intermediate hydrides and alkene complexes prior to reductive coupling that yield the alkyl lithium compound (RLi) in the hydrometallation reactor.

Catalysts for regeneration of RLi (e.g., BuLi) may compete with reactions that preferentially polymerize the alkene (e.g., 1-butene) at selected reaction conditions. Reactions that compete with regeneration of RLi can be mitigated by optimizing pressure (e.g., between about 1 atm and about 100 atm), and employing selected co-catalysts, activators including acids, and/or Lewis bases that favor or otherwise promote formation of RLi.

Catalysts that promote hydrometallation may also be immobilized on solid supports such as polystyrene or silica.

An alternate process may be used in the metallation reactor for formation or regeneration of alkyl-lithium (RLi) compounds, illustrated in reactions [10] and [11]: PhSH+C₄H₈(g)→BuSPh  [10] BuSPh+2Li(s)→PhSLi+BuLi  [11]

In reaction [10], alkenes such as butene may be reacted with thiophenol (PhSH) in the presence of a radical initiator such as azo-bis-isobutyronitrile [(CH₃)₂C(CN)₂N₂] (AlBN) or a suitable acid to form a phenylalkylthioether such as phenylbutylthioether (BuSPh). AlBN is soluble in organic solvents including alcohols. Concentration of AlBN in the solvent may be up to about 10% by mole. In reaction [11], the BuSPh product from reaction [10] may be reacted with lithium metal to form lithium phenyl sulfide (PhSLi) and RLi (e.g., BuLi) via reductive lithiation. Reaction [11] may provide a yield of BuLi or other RLi compounds at or above about 75%, more particularly at a yield greater than about 90%. BuLi and other RLi compounds may be more basic than PhSLi by several orders of magnitude, which permits their separation from the PhSLi, as detailed hereafter.

Separation of BuLi (RLi) and PhSLi

In some embodiments, RLi may be recoverable as a free product. For example, the PhSH reactant may be immobilized on a solid polymer support such as polystyrene, e.g., in a poly-PhSH form. Reaction of PhSH in reaction [10] may then form phenylbutylthioether (BuSPh) on the immobilized support, e.g., in a poly-PhSBu form. Reaction [11] then yields lithium phenyl sulfide (PhSLi) on the immobilized support in a poly-PhSLi form, and BuLi as an unattached moiety. BuLi formed in reaction [11] in the hydrometallation reactor may be readily separated from the immobilized poly-PhSLi product, e.g., by rinsing the surface of the immobilized poly-PhSLi product. With the RLi product recovered, the product poly-PhSLi that is immobilized on the polymer support may be converted back to the poly-PhSH form for re-use in the hydrometallation reactor as shown in [12]: PhSLi+HCl→LiCl+PhSH  [12]

LiCl recovered from reaction [12] may be recycled in an electrolysis stage described hereafter to regenerate Li metal. PhSH can be re-used for reaction [10] in the hydrometallation (catalyst) reactor. Recovered alkyl lithium compounds (e.g., BuLi) may be used in the metallation reactor to form the dialkyl-magnesium intermediate used to produce MgH₂ or a Mg metal product 2.

Electrolysis Stage

System 100 may also include an electrolysis stage 20 that converts LiCl 22 released as a reaction by-product from metallation reactor 12 into lithium metal (Li) 26 and chlorine (Cl₂) gas 32. Chlorine (Cl₂) gas 32 generated in electrolysis stage 20 may be collected, e.g., for commercial applications. Li metal 26 generated in electrolysis stage 20 may be recycled in hydrometallation reactor 16 in reactions [10] and [11] detailed previously to regenerate RLi 6. Electrolysis of LiCl 22 with corresponding collection of Cl₂ gas 32 minimizes potential for formation and emission of CO₂ gas stemming from high-temperature carbothermic reactions.

Eutectic mixtures of LiCl and KCl may be electrolyzed in an electrolytic cell described by Muller et al. in U.S. Pat. No. 4,740,279A. In some embodiments, various eutectic mixtures of LiCl and KCl may be electrolyzed at temperatures below about 400° C. to form Li metal. Electrolysis at these temperatures requires less energy than conventional MgCl₂ electrolysis. For example, the +1 valence, the low density, and low melting temperature of Li combined with a modest heat recovery (e.g., 12 kJ/mol) can lower the energy required for electrolysis by up to 50% compared with conventional MgCl₂ electrolysis at 900° C.

In some embodiments, a eutectic mixture of LiCl and KCl (molar ratios of about 58.5 mol % LiCl and about 41.5 mol % KCl) may be electrolyzed at a temperature of about 425° C., a gas pressure of about 1 atm (1.01×10² kPa), an operational voltage of 3.65V, and a current density of 2 A/cm². Li metal may be collected free of air and moisture and re-deployed in the hydrometallation reactor 16.

In some embodiments, eutectic mixtures can be electrolyzed to produce Li metal at temperatures as low as 243° C. In some embodiments, eutectic mixtures may be electrolyzed to produce Li metal at temperatures as low as 133° C.

In some embodiments, LiCl 22 obtained from metallation reactor 12 may be reacted with soda ash (Na₂CO₃) to precipitate lithium carbonate (Li₂CO₃). Precipitation can further remove impurities produced in metallation reactor 12. In some embodiments, electrolysis may employ Li₂CO₃ as the Li-containing salt. Energy consumed for electrolysis of Li₂CO₃ to Li metal is 42% lower than that required for the LiCl—KCl eutectic mixture, although no chlorine is produced. Electrolysis of Li₂CO₃ can reduce power consumption, and recover sufficient heat that may be employed in other processing steps.

In other embodiments, electrolysis may employ a eutectic mixture of LiCl and LiNO₃ (22.6 mol % and 87.4 mol %, respectively) at a temperature of about 243° C. At this temperature, Li metal can be produced with a thermal energy penalty about 50% lower than for electrolysis of mixtures of LiCl and KCl at 425° C.

Electrolysis may also eutectic mixtures of LiCl—KCl—NaCl (e.g., 43 mol %, 24 mol %, and 33 mol %, respectively) at a temperature of 357° C.

Energy not used in the electrolysis stage reduces overall energy consumption which enhances energy efficiency required for production of Mg metal 2.

Crystallization Stage

System 100 may further include a crystallization stage 34 such as a mineral extractor, a calciner, or a spray dryer that solidifies hydrated MgCl₂.nH₂O salts (where n=1, 2, 4, 6, or 12) received in a concentrated and/or and super-saturated salt brine liquid feedstock from a separator stage 38 described further herein. MgCl₂.nH₂O salts in the concentrated feedstock may include a concentration of Mg between about 40 wt % to less than or equal to about 94% Mg. The liquid feedstock may also contain minor quantities of impurity salts such as, e.g., NaCl, MgSO₄, KCl, and Na₂SO₄. Concentrated feedstocks may be dried at temperatures typically below 100° C., which yields crystallized MgCl₂.nH₂O salts 36 containing any minor quantities of impurity salts. Drying temperatures are not intended to be limited. Drying of concentrated feedstocks in crystallization stage 34 minimizes the energy-intensive step of evaporation of water used conventionally to crystallize MgCl₂.nH₂O salts.

Crystallized MgCl₂.nH₂O salts 36 may be separated from impurity salts by dissolving the MgCl₂.nH₂O salts in a selected polar organic solvent that impurity salts are not soluble in. Solvents suitable for use include, but are not limited to, e.g., alcohols (e.g., methanol), ethylene glycols, dimethyl-sulfoxide (DMS), dimethyl formamide (DMF), and other polar solvents.

Separating impurities from the MgCl₂.nH₂O salts 36 (≦94% Mg) increases the concentration of Mg in the MgCl₂.nH₂O salts 36 to greater than about 94% by weight (≧94% Mg). Separated MgCl₂.nH₂O salts obtained from crystallization stage 34 may be released to dehydration stage 24 described hereafter.

Dehydration Stage

System 100 may include an azeotropic dehydration stage 24 that yields anhydrous MgCl₂ 8 from concentrated MgCl₂.nH₂O salts 36 (≧94% Mg) received from crystallization stage 34. Anhydrous MgCl₂ 8 may be subsequently introduced to metallation reactor 12, as described previously.

Crystallized MgCl₂.nH₂O salts 36 do not readily or easily dehydrate by heating or calcining alone even under vacuum because the salts readily decompose to form hydroxychloride (MgOHCl), magnesium oxide (MgO), and HCl gas in the presence of moisture. Such reactions products are undesirable as they reduce the yield of Mg metal 2 ultimately obtained, increase waste by-products, and increase operating and processing costs.

MgCl₂.nH₂O salts 36 obtained from crystallization stage 34 may be delivered in the dissolved state in the polar solvent. An entrainer such as, e.g., benzene or toluene may be added to the solvent to facilitate separation of an alcohol-water azeotrope by selectively altering relative volatilities that permit removal/separation of waters of hydration from the dissolved MgCl₂.nH₂O salts via low-energy azeotropic distillation. The entrainer may be recovered by simple distillation or decantation that can then be recycled.

MgCl₂.nH₂O salts 36 received from crystallization stage 34 in the first polar solvent form soluble magnesium-containing adducts that separates waters of hydration from the hydrated salts, as shown in [13]: MgCl₂.6H₂O+C_(x)H_(2x+1)[OH]_(y)→MgCl₂.C_(x)H_(2x+1)[OH]_(y)+6H₂O(I)  [13]

For alcohol solvents, y=1 and x=1 to 4. For glycol solvents, y=2 and x=2 to 3.

Anhydrous ammonia may then be added to the magnesium-containing adducts to form a solid ammoniated MgCl₂ complex, as shown in [14]: MgCl₂.C_(x)H_(2x+1)[OH]_(y)+NH₃(g)→MgCl₂—NH₃—C_(x)H_(2x+1)[OH]_(y)(s)  [14]

Ammoniated magnesium salts may further ammoniate in the selected solvent to form MgCl₂ hexammoniate (i.e., MgCl₂.6NH₃). Heating the solid hexammoniate at a temperature less than or equal to about 450° C. deammoniates the solid and yields anhydrous MgCl₂ 8 at a purity of about 95% or better. Anhydrous MgCl₂ 8 obtained in dehydration stage 24 may be delivered to metallation reactor 12 for processing, as described previously herein. Both the organic solvent and ammonia used in dehydration stage 24 may be recovered and recycled. Heat recovered from the hot anhydrous MgCl₂ 8 may also be used to preheat another quantity of MgCl₂.6NH₃ solid.

Separator Stage

System 100 may also include a liquid separator 38 configured to remove or separate a bulk quantity of water and impurity salts from seawater and brine feedstocks that serves to concentrate magnesium-containing salts delivered to crystallizer stage 34, as described previously. Feedstocks containing magnesium-containing salts include, but are not limited to, e.g., seawater, salt brines, mineral effluents, effluents from metal process effluents, coal process effluents, biomass conversion effluents, and/or other mineral and salt sources. Separator 38 may release water and impurity salts as effluents.

FIG. 3 shows an exemplary pilot-scale system 300 for catalyzed organo-metathetical (COMET) production of magnesium metal, in accordance with the present invention. As will be appreciated by those of ordinary skill in the art, various configurations may be employed that implement novel and unique aspects of the system and process described previously in reference to FIG. 1. No limitations are intended by the exemplary embodiments described and presented herein. The COMET process produces Mg metal at a production cost up to about 50% lower than conventional processing.

The following example provides a further understanding of the present invention.

Example 1 Tests of Hydrometallation Catalysts

Exemplary hydrometallation catalysts were tested. The hydrometallation reactor included a 5% loading of each catalyst. The solvent selected for use was toluene. Tests were conducted at a temperature of 25° C. Results are listed in TABLE 1.

TABLE 1 CATALYST TEMPERATURE PRODUCT 1  

25 2-pentene 2  

25 2-pentene 3  

25 2-pentene 4  

25 2-pentene 5  

25 50% 1-pentene/ 50% 2-pentene 6  

25 74% 1-pentene 19% 2-pentene  7% pentane 7  

25 89% 1-pentene 11% pentane

Results demonstrate that listed catalysts are capable of hydrometallation of alkenes as shown by the isomerization of 1-pentene to 2-pentene. Formation of pentane also demonstrates that alkyllithium (RLi) is formed at a low yield ˜10%. As an example, pentyl lithium when formed in this process is very reactive and rapidly picks up a proton to form pentane.

While exemplary embodiments of the present invention have been shown and described, it will be apparent to those skilled in the art that many changes and modifications may be made without departing from the invention in its true scope and broader aspects. The appended claims are therefore intended to cover all such changes and modifications as fall within the spirit and scope of the present invention. 

What is claimed is:
 1. A process, comprising the steps of: forming a dialkyl magnesium compound by reacting an anhydrous magnesium-containing salt with an alkyl-lithium compound at a selected temperature, wherein the alkyl-lithium compound is obtained by reacting lithium metal and an olefin over a hydrometallation catalyst of the form Cp₂MX₂ or Cp₂MX(L), where (M) is a selected metal, (Cp) is cyclopentadiene, X is Cl, Br, and/or I, and the ligand (L) is a pyrrole, an amine, or a phosphinimine, or by reacting lithium metal with a phenylbutylthioether immobilized on a solid support; and decomposing the dialkyl magnesium compound to form magnesium hydride or magnesium metal.
 2. The process of claim 1, wherein the anhydrous magnesium-containing salt is anhydrous MgCl₂.
 3. The process of claim 1, wherein the alkyl-lithium compound and the dialkyl magnesium compound include an alkyl group with a carbon number selected between about C₂ to about C₈.
 4. The process of claim 1, wherein the alkyl-lithium compound and the dialkyl magnesium compound include an alkyl group that is a butyl group.
 5. The process of claim 1, wherein forming the dialkyl magnesium compound includes a transmetallation reaction at a selected temperature.
 6. The process of claim 1, wherein decomposition of the dialkyl magnesium compound includes formation of alkene hydrocarbons with a carbon number between about C₂ to about C₈.
 7. The process of claim 1, wherein the Mg metal product is a fully consolidated (dense) metal product, or a partially consolidated metal product.
 8. The process of claim 1, wherein the MgH₂ product is produced at a yield selected at or above about 90% by weight.
 9. A system, comprising: a hydrometallation stage that reacts lithium metal and an olefin over a selected hydrometallation catalyst forming an alkyl lithium compound; a metallation stage that reacts an anhydrous magnesium-containing salt with the alkyl-lithium compound at a selected temperature to form a dialkyl magnesium compound; and a decomposition stage that decomposes the dialkyl magnesium compound received from the metallation stage at a selected temperature to form magnesium hydride or magnesium metal in a selected form.
 10. The system of claim 9, wherein the metallation stage includes a transmetallation catalyst that forms the dialkyl magnesium compound at a temperature above about 250° C.
 11. The system of claim 9, wherein the decomposition stage decomposes the dialkyl magnesium compound in an inert atmosphere or under vacuum at a temperature above 150° C. and forms the consolidated magnesium metal product at a yield greater than or equal to about 90%.
 12. The system of claim 9, wherein the decomposition stage decomposes the dialkyl magnesium compound at a temperature at or below about 250° C. that forms MgH₂ at a yield at or above about 90% by weight that promotes consolidation of the magnesium metal product formed therein.
 13. The system of claim 9, wherein decomposition of the dialkyl magnesium compound in the decomposition stage includes formation of alkene hydrocarbons with a carbon number between about C₂ to about C₈. 